System for installation of photovoltaic devices on a structure

ABSTRACT

The present invention is premised upon a connector device and method that can more easily electrically connect a plurality of PV devices and/or locate these devices upon a building or structure in two rows/columns with opposing current flows. It also can optionally provide some additional components (e.g. a bypass diode and/or an indicator means) and can enhance the service-ability of the device.

CLAIM OF PRIORITY

The present application claims the benefit of the filing date of U.S.Provisional Application Nos. 61/050,341 (filed 5 May 2008); 61/098,941(filed 22 Sep. 2008); 61/149,451 (filed 3 Feb. 2009), the contents ofwhich are hereby incorporated by reference in their entirety.

This invention was made with U.S. Government support under contractDE-FC36-07G01754 awarded by the Department of Energy. The U.S.Government has certain rights in this invention.

FIELD OF THE INVENTION

The present invention relates to an improved photovoltaic deviceassembly and method of making same, more particularly to an improvedphotovoltaic device assembly (kit) with opposing current flows inadjoining rows or columns and method of making same for providing solarpower.

BACKGROUND

Efforts to improve photovoltaic devices or “PV devices”, particularly toimprove the connection, installation, and service of multiple devicesare subject to continuing development within the PV industry. Of specialinterest are those PV devices that are integrated into buildingstructures or fascia (e.g. roofing shingles, exterior wall surfaces,canopies, awnings), or stand alone PV systems (e.g. solar farms). To aidin their commercial and functional viability, they should satisfy anumber of criteria. The individual devices and the overall assembly(sometimes known as a kit) should be robust, that is they should be ableto remain functional in a myriad of environmental conditions (e.g. heat,cold, wind, rain, snow, etc.). In the case of building structures, theyshould also not subject the building structure to overly adversemodifications due to their presence, such as multiple roof penetrationsmade to electrically connect and/or locate the plurality of devices,resulting in the roof which could have to be subsequently sealed againstleaks. The roof penetrations and/or extensive electricalwiring/connections can make installation time consuming and expensive.In either a building structure or stand alone PV system, the relativeease of installation provided by the present invention can beadvantageous. Furthermore, when a device component (e.g. a single paneland/or a sub-component such as a bypass diode) does become damaged orneeds to be replaced, it can be valuable to have a system that allowseasy replacement of the device component or sub-component.

Among the literature that can pertain to this technology include thefollowing patent documents: US20080190047(A1); U.S. Pat. No. 4,321,416;U.S. Pat. No. 5,575,861; U.S. Pat. No. 5,437,735; U.S. Pat. No.5,990,414; U.S. Pat. No. 6,840,799; EP1744372; U.S. Pat. No. 6,875,914;U.S. Pat. No. 5,590,495; U.S. Pat. No. 5,986,203; US2008/0115822;EP1923920; U.S. Pat. No. 7,365,266; US20070295393 A1; US20070295392 A1;and WO 2008/139102, U.S. Provisional Application Nos. 61/050,341 (filed5 May 2008); 61/098,941 (filed 22 Sep. 2008); 61/149,451 (filed 3 Feb.2009), and PCT Applications filed concurrently for attorney docket Nos.67558-WO-PCT (1062A-016WO); 67666-WO-PCT (1062A-017WO); and 66746-WO-PCT(1062A-012WO) filed concurrently with the present application, allincorporated herein by reference for all purposes.

SUMMARY OF THE INVENTION

The present invention is directed to a solution to at least one or moreof the issues described above. Particularly, the present invention seeksto provide a robust photovoltaic device assembly and method that canmore easily electrically connect a plurality of PV devices (whileminimizing the total number of electrical connections in the kit) and/orlocate these devices upon a structure (e.g. a building wall, buildingroof, or platform). It also can optionally provide some additionalcomponents (e.g. a spacer piece/device and/or connector pieces) and canenhance the serviceability of the device.

Accordingly, pursuant to a first embodiment of the present invention,there is contemplated a photovoltaic device kit including: a. at least aplurality of photovoltaic devices in at least a first and a second rowor column as applied to a structure, the photovoltaic device including:i. a photovoltaic cell assembly including at least one peripheral edge,at least one photovoltaic cell inboard of the at least one peripheraledge, which the photovoltaic cell includes a photoactive portion,wherein the at least one photovoltaic cell includes a surface thatallows transmission of light energy to the photoactive portion forconversion into electrical energy; ii. at least one positive bussterminal and at least one negative buss terminal for transferringcurrent to or from the photovoltaic cell assembly via at least oneintegral photovoltaic connector assembly located within the at least oneperipheral edge; and iii. a body portion including lower surface portionthat contacts the structure, and an upper surface portion that receivesa fastener that attaches the photovoltaic device to the structure,wherein the body portion is at least partially joined to at least oneedge portion of the photovoltaic cell assembly along at least a portionof a bottom segment of the body portion while leaving the surface of theat least one photovoltaic cell exposed; b. at least one edge piecedisposed at the end or within the at least upper and adjoining lower rowof photovoltaic devices, the at least one edge piece including at leastone edge connector assembly for connecting each respective row ofphotovoltaic devices; wherein a current flow across the first row orcolumn in one direction and across the second row or column in theopposite direction.

Accordingly, pursuant to a second embodiment of the present invention,there is contemplated a photovoltaic device assembly including: a. aplurality of first photovoltaic devices individually interconnected viaa plurality of photovoltaic device connector assemblies in a first row,wherein a current flow is created in a first direction; b. a pluralityof discrete second photovoltaic devices individually interconnected viathe plurality of photovoltaic device connector assemblies in a secondrow, wherein the current flow is created in an opposing direction fromthe current flow of the first photovoltaic devices; and c. a first edgepiece spanning between and connecting the first and second rows at oneend.

The invention of both the first and/or second embodiments can be furthercharacterized by one or any combination of the features describedherein, such as including at least one spacer device connected betweentwo photovoltaic devices, one photovoltaic device and one edge piece, orboth; the at least one edge piece includes a building connector assemblyor electrical lead assembly; the at least one integral photovoltaicconnector assembly, the at least one edge connector assembly, or bothinclude a strain relief feature; the at least one integral photovoltaicconnector assembly, the at least one edge connector assembly, or both,further includes an integral connector housing adapted to receive aconnector element; the connector element comprises: a. a base portionincluding a first end portion, a second end portion, an intermediateportion and an outer surface; b. a locator portion located on the outersurface of the intermediate portion, the locator portion including abearing wall that is shaped to generally complement the integralconnector housing; and c. at least one electrically conductive memberthat is substantially surrounded by the base portion and that spansbetween the first and second end portions and includes connectiveterminals at opposing ends that are shaped to interlock with an opposingterminal in the integral connector housing, so that the bearing wallpartially contacts an opposing surface in the integral connectorhousing; the at least one edge piece includes at least one edgeconnector assembly for connecting to a second edge piece; the at leastone edge piece includes an indicator device to communicate a circuitstatus; the structure is a building.

Looking more towards the second embodiment, it can be furthercharacterized by one or any combination of the features describedherein, such as including a second edge piece spanning between andconnecting the first and second rows at an opposing end, wherein atleast the first edge piece includes a first electrical circuit thatincludes at least a pass-though electrical connector or electrical leadassembly and wherein at least the second edge piece includes a secondelectrical circuit that includes at least an electrical return circuitinterconnect; the plurality of discrete first photovoltaic devices andthe plurality of discrete second photovoltaic devices comprise: a. aphotovoltaic cell assembly including at least one peripheral edge, atleast one photovoltaic cell inboard of the at least one peripheral edge,which the photovoltaic cell includes a photoactive portion, wherein theat least one photovoltaic cell includes a surface that allowstransmission of light energy to the photoactive portion for conversioninto electrical energy; b. at least one positive buss terminal and atleast one negative buss terminal for transferring current to or from thephotovoltaic cell assembly via at least one integral photovoltaicconnector assembly located within the at least one peripheral edge; andc. a body portion including lower surface portion that contacts astructure, and an upper surface portion that receives a fastener thatattaches the photovoltaic device to the structure, wherein the bodyportion is at least partially joined to at least one edge portion of thephotovoltaic cell assembly along at least a portion of a bottom segmentof the body portion while leaving the surface of the at least onephotovoltaic cell exposed; the body portion and at least one peripheraledge at least include a unitary polymeric portion; the first edge pieceand the second edge piece comprise a polymeric body that substantiallyenvelops at least a portion of the first and second electrical circuitsrespectfully; the integral photovoltaic connector assembly includes alocator feature for locating one of the plurality of discrete firstphotovoltaic devices and the plurality of discrete second photovoltaicdevices to another or to the first or second end piece within therespective row; the first row, second row, or both, include at least onespacer device; the structure is a building.

Accordingly, pursuant to a third embodiment of the present invention,there is contemplated a method of constructing a photovoltaic deviceassembly on a surface of a structure, including the steps of: a.providing a plurality of individual photovoltaic devices, wherein theindividual photovoltaic devices include: i. a photovoltaic cell assemblyincluding at least one peripheral edge, at least one photovoltaic cellinboard of the at least one peripheral edge, which the photovoltaic cellincludes a photoactive portion, wherein the at least one photovoltaiccell includes a surface that allows transmission of light energy to thephotoactive portion for conversion into electrical energy; ii. at leastone positive buss terminal and at least one negative buss terminal fortransferring current to or from the photovoltaic cell assembly via atleast one integral photovoltaic connector assembly located within the atleast one peripheral edge; and iii. a body portion including lowersurface portion that contacts the structure, and an upper surfaceportion that receives a fastener that attaches the photovoltaic deviceto the structure, wherein the body portion is at least partially joinedto at least one edge portion of the photovoltaic cell assembly along atleast a portion of a bottom segment of the body portion while leavingthe surface of the at least one photovoltaic cell exposed; b. providinga plurality of edge pieces; c. attaching a first individual photovoltaicdevice to the surface; d. attaching a second individual photovoltaicdevice to the first individual photovoltaic device via a connectorelement; e. attaching the second individual photovoltaic device to thesurface; f. repeat steps c-e until a first row is attached to thesurface, wherein a current flow can flow in a first flow direction; g.begin attaching a second row of individual photovoltaic devices adjacentto the first row, using the same steps as the first row except that thecurrent flow is in a second flow direction; and h. attaching at leastone edge piece via a connector element to at least one end of the firstand second row.

The invention of the third embodiment can be further characterized byone or any combination of the features described herein, such asincluding the step of providing a spacer device; the first row, secondrow, or both, include at least one spacer device in place of at leastone of the individual photovoltaic devices; the steps c-h are repeatedto create the photovoltaic device assembly with a plurality of rows; aseparate connector element is provided which includes: i. a base portionincluding a first end portion, a second end portion, an intermediateportion and an outer surface; ii. a locator portion located on the outersurface of the intermediate portion, the locator portion including abearing wall that is shaped to generally complement the integralconnector housing; and iii. at least one electrically conductive memberthat is substantially surrounded by the base portion and that spansbetween the first and second end portions and includes connectiveterminals at opposing ends that are shaped to interlock with an opposingterminal in the integral connector housing, so that the bearing wallpartially contacts an opposing surface in the integral connectorhousing; some or all of the plurality of connector elements have thefirst end portion integral to the edge piece, the photovoltaic device,or both; the structure is a building.

It is also should be appreciated that the present invention contemplatesa photovoltaic device assembly and method comprising a plurality of PVdevices of any of the embodiments described above or subsequently inthis application.

It should be appreciated that the above referenced embodiments andexamples are non-limiting, as others exist within the present invention,as shown and described herein.

DESCRIPTION OF THE DRAWINGS

FIG. 1 is an exemplary illustration of a perspective view of anassembled kit (row) according to the present invention.

FIG. 1A is an exemplary illustration of a schematic of the one possibleassembled kit derivation shown in FIG. 1, according to the presentinvention

FIG. 2 is another exemplary illustration of a schematic of the onepossible assembled kit derivation shown in FIG. 1, according to thepresent invention.

FIG. 3 is a partial exploded view of the bottom two rows (left side) ofthe kit of FIG. 2.

FIG. 4 is one exemplary illustration of an exploded view of a PV devicepiece according to the present invention.

FIG. 5 is an exemplary illustration of a perspective view of a connectorpiece according to the present invention.

FIG. 6 is an exemplary illustration of an exploded perspective view oftwo PV devices and the connector of FIG. 5.

FIG. 7 is an exemplary illustration of a perspective view of a partiallyintegrated connector.

FIG. 8 is an exemplary illustration of a perspective view (top) of onepossible edge piece according to the present invention.

FIG. 9 is an exemplary illustration of a perspective view (bottom) ofone possible edge piece according to the present invention.

FIG. 10 another exemplary illustration of a perspective view (bottom) ofan edge piece with ribs and integrated wiring according to the presentinvention

FIG. 11 another exemplary illustration of a perspective view (bottom) ofan edge piece with ribs and a wiring channel according to the presentinvention.

FIG. 12 is a perspective view of ribs and wiring channel of FIG. 11

FIG. 13 is an exemplary illustration of a schematic of one possible kitderivation according to the present invention.

FIG. 14 is an exemplary illustration of a row of PV devices with aspacer device.

FIG. 15 is an exemplary illustration of a perspective view of anassembled kit (column) according to the present invention.

FIG. 16 is an exemplary illustration of a schematic of one possible kit(column) derivation according to the present invention.

FIG. 17 an exemplary illustration of two perspective views (top andbottom) of a PV device (column kit) according to the present invention.

FIG. 18 an exemplary illustration of two perspective views (top andbottom) of an edge piece (column kit—top) according to the presentinvention.

FIG. 19 an exemplary illustration of a perspective view of a structurepass-through electrical connector assembly.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT

The present invention is a photovoltaic device assembly (or kit) andmethod of making same. This assembly can include a plurality ofphotovoltaic devices (“PV devices” or “PVD”) that are placed in rows orcolumns (e.g. two or more); wherein the devices can be both physicallyand electrically connected by connectors, edge pieces, spacer pieces, orany combination thereof. The assembly is configured to aid in providingquick and easy installation and to reduce the number of potentialstructure, (façade or roof—in the case of the preferred structure of abuilding roof application) penetrations needed. Preferably, thephotovoltaic device assembly utilizes PV devices and connectors that arethe same or similar (functionally and/or structurally) to thosedescribed in U.S. patent application Ser. Nos. 61/050,341, 61/098,941,and 61/149,451 all hereby incorporated by reference for all purposes.

Generally, the present invention contemplates a photovoltaic deviceassembly or kit 20 (for example as a row configuration as shown in FIGS.1, 1A, and 2 fully assembled and for example as a column configurationfully assembled as shown in FIG. 15 and FIG. 16) that can include atleast a plurality of PV devices 100 in at least two rows or columns asapplied to a building (or other structure). As shown in FIG. 2, thewiring at the bottom of the kit 20 may be routed up and across (e.g. viachannels 65) assembled kit 20 so that the electrical wires are at ornear the top of the kit. The first row/column configured to produce acurrent flow 21 (shown with an arrow) in one direction and the secondrow configured to have an opposite current flow. The kit 20, can includeat least one edge piece 50 located at the end or within the at least tworows/columns of PV devices 100. The PV devices 100 can be furtherdescribed as at least including a photovoltaic cell assembly 110 and abody portion 120.

The edge piece 50 may include two or more edge connector assemblies 52for connecting each respective row or column of photovoltaic devices.The edge piece can include electrical element or elements 51incorporated between edge connector assemblies 52 such that the rows areelectrically connected together or have a single electrical output 500from the kit 20 at or near an outer edge of the kit. In certain cases,the edge piece may have no electrical connector assemblies 52 andfunction solely as a filler piece 54 or a starter piece 53. Preferably,the edge connector assemblies and the photovoltaic device connectorassemblies 58 are the same or similar (e.g. functionally and/orstructurally). A description for one is intended to apply to the otherunless specifically stated otherwise. The edge piece connector assemblycan be, as in the first embodiment, integral to the edge piece (i.e.located within at least one peripheral edge of an edge piece as is shownin FIG. 3) or it can be a separate element that is used in the assemblybetween one peripheral edge of an edge piece and one peripheral edge ofa PV device or between peripheral edges of adjacent edge pieces andmating to the connector housing or connector elements in those pieces,depending on the kit design.

The edge piece connector assembly 52 can include a housing 56 integralto the edge piece (e.g. a female housing), as shown in the PV device inFIG. 6, adapted to receive a separate connector piece 58 (i.e., shapedto generally complement an opposing connector housing), a connectorintegrated housing 59 with a connector piece at least partiallyintegrated therein (FIG. 7), or any combination thereof and at least oneelectrically conductive member that spans between the first and secondend portions and includes connective terminals at opposing ends that areshaped to interlock with an opposing terminal in the opposing connectorhousing.

The assembly can also include any number of spacer pieces 400 (e.g. asshown in FIG. 14) that may or may not contain any photovoltaic devices(e.g. power generating means) or other components. It is contemplatedthat spacer pieces can provide additional functionality to the kit. Inone example, a spacer piece 400 can provide a through hole for roofvents. In another example, a spacer piece 400 or pieces can provide anaesthetic function, such as staggering the rows or columns.

It is also contemplated that the assembly or kit can be configured toprovide a targeted power output (e.g. 0.1 to 8 KWp or more (KWp definedas kilowatt-peak) and to fit standard building designs (e.g. massproduced homes) that share roof and/or fascia layouts, or can be customconfigured for one-off designs. For example, the kit can be configuredto fit (e.g. number of PV devices, number of rows, number and locationof spacers/edge pieces) one particular roof design that is utilized in aparticular model home offered by a builder (e.g. the Beaumont™ modeloffered by Pulte Homes™)

The individual components that make up the kit are described in furtherdetail and illustrative examples of some of the possible kitconfigurations are provided below.

PV Device

In an illustrative example, the PV device 100 can be described generallyas a three dimensional article that includes an energy producing device(e.g. solar cells), electrical circuitry to transfer the energyproduced, and a body which holds the energy producing device and allowsit to be effectively mounted onto a structure. It is contemplated that aPV device 100 of the present invention is preferably a discretepart/component that is used in the overall kit. It is also contemplatedthat the PV devices used in one row/column are configured to have acurrent flow 21 in one direction and the PV devices used in an adjoiningor second row/column are configured to have a current flow 21 in anopposing direction. It may also be described that the PV devices of onerow/column have one polarity while the PV devices of the secondrow/column have an opposite polarity.

For example, as shown in FIG. 3, the PV device 100 can be furtherdescribed as including a photovoltaic cell assembly 110 and a bodyportion 120 (which can also be referred to as a body support portionwhere it provides structural support). The body portion 120 having anupper surface portion 122, a lower surface portion 124 and side wallportion 126 spanning therebetween. The body portion 120 can be furtherdescribed as including a main body portion 222, a side body portion 224,and an optional bottom body portion 226 and locator (not shown). The PVdevice 100 can also be described as having an active portion 130 and aninactive portion 135. The active portion 130 can include at least thephotovoltaic cell assembly 110, a portion of the side body portion 224and the optional bottom body portion 226. The inactive portion 135 caninclude at least the main body portion 222, a portion of the side bodyportion 224, and some or all of the electrical circuitry of the PVdevice 100.

For example as shown in an exploded view of a PV device 100 in FIG. 4,the photovoltaic cell assembly 110 can be further described as includinga photovoltaic cell 111, protective layers 113, and at least some of theelectrical circuitry 114 of the PV device. The PV devices 100 can alsobe described in an alternative fashion. The PV devices 100 can includecomponents such as the photovoltaic cell assembly 110, at least onepositive buss terminal 140 and at least one negative buss terminal141(not shown), and a body portion 120.

The PV devices 100 can include at least one peripheral edge 112, atleast one photovoltaic cell 111 inboard of the at least one peripheraledge 112.

The positive and negative buss terminals 140, 141, which can function totransfer current to or from the photovoltaic cell assembly 110 via atleast one integral photovoltaic connector assembly 57 located within theat least one peripheral edge 112. Preferably, the positive and negativebuss terminals 140, 141 are located on opposing edges of the PV deviceand each transfer current via an integral connector assembly 57 disposedin opposing peripheral edges. For example, the PV device used in thefirst row have the positive buss terminal 140 on the right side of thePV device and the negative buss terminal 141 on the left side, in thesecond row this is reversed. In the case of a column, the positive bussterminal 140 is on top and the negative on the bottom for the firstcolumn and reversed on the adjoining column.

The body portion 120 lower surface portion 124 can contact the structure(e.g. building substrate and/or structure). Also having an upper surfaceportion 122 that receive a fastener (not shown, e.g. nail, screw,staple, rivet, etc.) that attaches the photovoltaic device 100 to thestructure. Furthermore, the body portion 120 can be at least partiallyjoined to at least one edge portion of the photovoltaic cell assembly110 along at least a portion of a bottom segment 156 of the body portion120 while leaving at least a portion of the at least one photovoltaiccell 111 exposed to receive radiation.

It is contemplated that the PV device 100 can be constructed at leastpartially of flexible materials (e.g. thin films or deformablematerials, with significant plastic or elastic elongation such asplastics, synthetic and natural rubbers, films, elastomers, or the like)to allow at least some flexibility for conforming to an irregularcontour in a building structure. It is also contemplated that it can bedesirable to at least keep the photovoltaic cell relatively rigid,generally to prevent any cracking of the cell. Thus, some parts of thePV device can be constructed with a more rigid material (e.g. glassplate, mineral filled composites, or polymeric sheets). Although, thephotovoltaic cell can be partially or substantially rigid, it ispossible for the PV device to be generally flexible. For this invention,flexible means that the PV device is more flexible or less rigid thanthe substrate (e.g. structure) to which it is attached. Preferably, inthe case of a flexible substrate the PV device can bend about a 1 meterdiameter cylinder without a decrease in performance or critical damage.Preferably, in the case of a rigid substrate the PV device can bendabout 20 meter diameter cylinder without a decrease in performance orcritical damage. For example, in the case of a PV device shingle,shingles generally are less rigid than the roof deck; the roof deckprovides structural rigidity. In some other examples the roofing productitself provides the necessary rigidity and the roof deck is absent, orminimized.

The photovoltaic cell 110, contemplated in the present invention may beconstructed of any number of known photovoltaic cells commerciallyavailable or may be selected from some future developed photovoltaiccells. These cells function to translate light energy into electricity.The photoactive portion of the photovoltaic cell is the material whichconverts light energy to electrical energy. Any material known toprovide that function may be used including crystalline silicon, oramorphous silicon. However, the photoactive layer is preferably a layerof IB-IIIA-chalcogenide, such as IB-IIIA-selenides, IB-IIIA-sulfides, orIB-IIIA-selenide sulfides. More specific examples include copper indiumselenides, copper indium gallium selenides, copper gallium selenides,copper indium sulfides, copper indium gallium sulfides, copper galliumselenides, copper indium sulfide selenides, copper gallium sulfideselenides, and copper indium gallium sulfide selenides (all of which arereferred to herein as CIGSS). These can also be represented by theformula CuIn(1-x)GaxSe(2-y)Sy where x is 0 to 1 and y is 0 to 2. Thecopper indium selenides and copper indium gallium selenides arepreferred. Additional electroactive layers such as one or more ofemitter (buffer) layers, conductive layers (e.g. transparent conductivelayers) and the like as is known in the art to be useful in CIGSS basedcells are also contemplated herein. These cells may be flexible or rigidand come in a variety of shapes and sizes, but generally are fragile andsubject to environmental degradation. In a preferred embodiment, thephotovoltaic cell assembly 110 is a cell that can bend withoutsubstantial cracking and/or without significant loss of functionality.Exemplary photovoltaic cells are taught and described in a number of USpatents and publications, including U.S. Pat. No. 3,767,471, U.S. Pat.No. 4,465,575, US20050011550 A1, EP841706 A2, US20070256734 al,EP1032051A2, JP2216874, JP2143468, and JP10189924a, incorporated heretoby reference for all purposes.

Connector

It is contemplated that the kit 20 may use a plurality of connectors 58,for example such as those described in U.S. provisional application61/098,941 hereby incorporated by reference. These connectors can beseparate components (e.g. as shown in FIGS. 5-6) or partially integratedinto the PV device 100, the edge piece 50, or both (e.g. as shown inFIG. 7). In an illustrative example shown in FIG. 5, the connector 58can be described generally as including a base portion 210 including afirst end portion 212, a second end portion 214 and an outer surface216. It also can include a locator portion 218 located on the outersurface. In one particular embodiment, the locator portion can bedescribed as including a bearing wall that can be shaped to generallycomplement an opposing female connector housing 56 that can be locatedin a PV device 100 or edge piece 50. Furthermore, upon installation, thebearing wall can at least partially contact an opposing surface in thefemale connector housing. Moreover, the connector assembly can includeat least one electrically conductive member that is substantiallysurrounded by the base portion and that spans between the first andsecond end portions and includes connective terminals at opposing ends.These terminals can be shaped to interlock with an opposing terminal inthe opposing female connector housing.

It is also contemplated that the opposing female connector housing canbe integral to an outer wall section (e.g. portions such as top, bottom,or sides of the PV device or edge piece) of the PV device 100 or edgepiece 50. The housing can be connected to the PV device or edge piecevia a fastener scheme (e.g. mechanical fasteners, adhesives, or acombination thereof) or can be integrated into the PV device or edgepiece via the structure of the device/piece (e.g. over-molded into thedevice or part of the framework of the PV device or edge piece forexample as shown in FIG. 10). In either case, it is contemplated thatfemale connector housing integral to or connected to a PV device or edgepiece and/or the connector assembly includes a strain relief feature (orcombination of one or more features) to allow movement of the assemblywhile maintaining an electrical contact between the respectiveterminals.

The edge piece connector assembly may be further characterized by one orany combination of the features described herein, such as the opposingfemale connector housing is integral to an outer wall section of theedge piece or the photovoltaic device; the connector assembly includes abypass diode electrically connected to the at least one electricallyconductive member; the connector assembly includes an indicator deviceto communicate a circuit status; the connector assembly includes alocking device that locks the male connector element to the opposingfemale connector housing upon installation; the connector assemblyincludes a second electrically conductive member, the first end portionof which is integral to the outer wall section of the photovoltaicdevice or edge piece, the connector element (male or female) is integralto the first connector housing (male or female), an outwardly projectingportion in the locator portion that projects upward towards a topsurface that is generally coplanar with a top surface of thephotovoltaic device or edge piece.

It should be appreciated that the above referenced aspects and examplesare non-limiting, as others exist within the present invention, as shownand described herein.

Edge Piece

The edge piece 50, for example as shown in FIGS. 8-11 and 18, generallyfunction to physically and/or electrically connect at least two rows orcolumns of PV devices 100. It can also function to connect one edgepiece to another edge piece. The edge piece 50 can be disposed at asingle end, opposing ends, within a row/column, or any combinationthereof of a row/column of PV devices 100. It is contemplated that anedge piece 50 can include a through roof (or building structure)connector feature (e.g. a structure pass-through electrical connectorassembly 510) or electrical leads or insulated wires (e.g. electricallead assembly) that allow for the electrical output of the PV device ordevices to be electrically connected to the complimentary electricaldevices located within the structure. It is also contemplated that afiller piece 54 may be used to fill any possible gaps in the edge pieceswhen assembled. The edge piece can be attached to the structure in thesame manner as the PV device 100, for example with a fastener such as anail or screw being driven through a portion of the body. The fastenerpreferably being placed in an area that does not contain any additionalcomponents (e.g. wires, connectors and the like). It is contemplatedthat a fastening zone (not shown) can be marked on the edge piece to aidin installation (e.g. physical markings on the PV device, edge piece, orboth such as “nail here” or “fastener” or some other graphicaldemarcation). The edge piece 50 can also include additional componentssuch as electrical transmission lines (e.g. wires), electrical switches,fuses, by-pass diodes, solar cells, circuit status indicators, or anycombination thereof.

As shown in FIGS. 8-13, it is contemplated that the main body portion 60can have an outer surface portion 62, an inner surface portion 64 (e.g.portion that contacts the building or structure surface) and sidesurface portions 66 that connect the outer and inner surface portions62, 64. Optionally, the inner surface portion 64 can be solid (e.g. aunitary block) or have geometric features (e.g. ribs 61 for example asshown in FIG. 10). The main body portion 60 can be any number of shapesor sizes, but preferably is shaped to complement the shape of the PVdevice 100 that it connects thereto. In this example, the main bodyportion 60 is “stepped” vertically to allow for a complementary fit totwo rows of PV devices that are stacked and layered (e.g. akin toroofing shingles). The main body portion 60 can also be “staggered”horizontally to allow for a complimentary fit to the two rows of PVdevices, if the devices are installed with an offset (again, akin toroofing shingles). It also can include a flashing portion 68 that can beadapted to interface with and/or sit under other building materials(e.g. abutting standard roofing shingles, trim materials, buildingsiding, or the like).

In one illustrative example, shown in FIG. 9, a bottom view of an edgepiece 50 can be described generally as including a main body portion 60and two edge connector assembly 52 (one example of which may be “thepartially integrated connector assembly” as described above) and anelectrical element or elements 51 (e.g. wires, electrically conductivefoil or polymers) spanning between the two edge connector assemblies 52,one of which is hidden behind the body portion 60 of the edge piece.

In another illustrative example shown in FIG. 10, (an alternative bottomview of an edge piece) the electrical element 51 can be integrallyconnected to the edge piece 50 (e.g. molded within the piece).Preferably, the element is wire or foil pieces that are molded into theedge piece 50 (partially or fully encapsulated by the edge piece) alongwith at least a portion of the connector assembly 52.

In yet another illustrative example, shown in FIGS. 11-12 (also bottomviews of the edge piece), the electrical element 51 can be removablyattached via any number of attachment features (e.g. adhesive,mechanical fasteners, press-fit into channels 65, for example, cut intoribs 61, shown in FIG. 12, or any combination thereof). It iscontemplated that the PV devices 100 may also include ribs 61 withchannels 65 for any required wire routing.

The main body portion 60 can be constructed of any number of materials(e.g. polymers, metals and/or ceramics), so long as it resistsenvironmental degradation as it is exposed to the outdoor over the yearsof service (e.g. 10, 20 or 30 years or more). Preferred materials orcombinations of materials include a filled or unfilled moldable plastic(e.g. polyolefins, acrylonitrile butadiene styrene, hydrogenated styrenebutadiene rubbers, polyester amides, polysulfone, acetel, acrylic,polyvinyl chloride, nylon, polyethylene terephthalate, polycarbonate,thermoplastic and thermoset polyurethanes, synthetic and naturalrubbers, epoxies, styrene-acrylonitrile (“SAN”), polymethylmethacrylate, polystyrene, or any combination thereof). Fillers caninclude one or more of the following: colorants, fire retardant (“FR”)or ignition resistant (“IR”) materials, reinforcing materials, such asglass or mineral fibers, surface modifiers. Plastic can also includeanti-oxidants, release agents, blowing agents, and other common plasticadditives.

ILLUSTRATIVE EXAMPLES

The various examples discussed below and shown in the figures generallyattempt to take PV devices, edge pieces, connectors and optionally othercomponents (e.g. spacers 400 as shown in FIG. 14) to create aphotovoltaic device kit 20 that when assembled can be configured toprovide a targeted power output and preferably require two or lesselectrical connections to the inverter or the underlying buildingelectrical system. It is contemplated that the geometry of these kitscan be varied and the following examples should not be considered aslimiting. Thus, for the sake of clarity, the following examples areprovided to illustrate the invention but are not intended to limit thescope thereof. The rows of PV devices can be staggered (e.g. astraditional roofing shingles) or lined up in columns. The rows and/orcolumns can be vertical, horizontal or anywhere in-between. In all theillustrative examples discussed below, it is assumed that the PV devicescan be physically and electrically connected to one another within therow via connector assemblies as described previously. The lines 600shown represent the electrical transmission line or circuits within thePV devices 100 and/or the edge pieces 50 and the dots representconnectors.

Referring to FIG. 13, a first illustrative example of the presentinvention is shown (schematical view). In example, a photovoltaic devicekit 20 can include at least a plurality of PV devices 100 in multiplerows and multiple edge pieces 50 (one set on each row end). At both endsof a row of PV devices 100, the PV devices can be physically andelectrically connected to an edge piece 50 via and edge piece connectorassembly 52. The edge piece can include electrical element or elements51 that electrically connect the rows together and have two electricaloutputs 500 from the kit 20 at or near an inner edge of the kit.

It is contemplated that the electrical output 500 may be accomplishedvia a pass-through electrical connector assembly 510 (for example asshown in FIG. 19 as a part of a connector assembly) or electrical leadassembly (for example a set of wires attached to an edge piece or aconnector assembly—not shown)

Referring to FIG. 14, a single row of PV devices 100 including anexemplary spacer piece 400 is shown.

According to another embodiment, tile style installations (e.g. columns)are preferably arranged as shown in FIGS. 15 and 16. Referring to FIGS.15-18, a second illustrative example of the present invention is shown.In this example, one possible vertical configuration of PV devices 100is shown (e.g. 2 rows×3 columns). In this example 3 columns of PVdevices 100 include a flow channel 1100 on one side that can aid inwater flow control and/or provide an interlocking function. Also, edgepieces 50 are provided with geometry appropriate to fit in this verticalconfiguration and with different geometries between edge pieces at thetop of the column versus the bottom of the column (e.g. as seen in FIG.18). The fully assembled kit 20 is shown in FIGS. 15 and 16. Also shownin this example are ribs 61 that are formed on the back side of the PVdevices and edge pieces. These ribs 61 can help reduce the mass of thecomponents and aid in providing the desired rigidity for the components.Rib designs can be incorporated into both the vertical (column) andhorizontal (row) examples or embodiments.

In FIG. 16, a schematic of one possible electrical circuit is shown withconnectors 52 and electrical element 51 (wiring preferably integral tothe PV devices and edge pieces. In the vertical configuration of the kit20, the physical and electrical connections to the PV devices 100 occurat or near the top and bottom of the devices (versus at the sides as inthe row configurations described in the earlier examples).

Unless stated otherwise, dimensions and geometries of the variousstructures depicted herein are not intended to be restrictive of theinvention, and other dimensions or geometries are possible. Pluralstructural components can be provided by a single integrated structure.Alternatively, a single integrated structure might be divided intoseparate plural components. In addition, while a feature of the presentinvention can have been described in the context of only one of theillustrated embodiments, such feature can be combined with one or moreother features of other embodiments, for any given application. It willalso be appreciated from the above that the fabrication of the uniquestructures herein and the operation thereof also constitute methods inaccordance with the present invention.

The preferred embodiment of the present invention has been disclosed. Aperson of ordinary skill in the art would realize however, that certainmodifications would come within the teachings of this invention.Therefore, the following claims should be studied to determine the truescope and content of the invention.

Any numerical values recited in the above application include all valuesfrom the lower value to the upper value in increments of one unitprovided that there is a separation of at least 2 units between anylower value and any higher value. As an example, if it is stated thatthe amount of a component or a value of a process variable such as, forexample, temperature, pressure, time and the like is, for example, from1 to 90, preferably from 20 to 80, more preferably from 30 to 70, it isintended that values such as 15 to 85, 22 to 68, 43 to 51, 30 to 32 etc.are expressly enumerated in this specification. For values which areless than one, one unit is considered to be 0.0001, 0.001, 0.01 or 0.1as appropriate. These are only examples of what is specifically intendedand all possible combinations of numerical values between the lowestvalue and the highest value enumerated are to be considered to beexpressly stated in this application in a similar manner.

Unless otherwise stated, all ranges include both endpoints and allnumbers between the endpoints. The use of “about” or “approximately” inconnection with a range applies to both ends of the range. Thus, “about20 to 30” is intended to cover “about 20 to about 30”, inclusive of atleast the specified endpoints.

The disclosures of all articles and references, including patentapplications and publications, are incorporated by reference for allpurposes.

The term “consisting essentially of” to describe a combination shallinclude the elements, ingredients, components or steps identified, andsuch other elements ingredients, components or steps that do notmaterially affect the basic and novel characteristics of thecombination.

The use of the terms “comprising” or “including” to describecombinations of elements, ingredients, components or steps herein alsocontemplates embodiments that consist essentially of the elements,ingredients, components or steps.

Plural elements, ingredients, components or steps can be provided by asingle integrated element, ingredient, component or step. Alternatively,a single integrated element, ingredient, component or step might bedivided into separate plural elements, ingredients, components or steps.The disclosure of “a” or “one” to describe an element, ingredient,component or step is not intended to foreclose additional elements,ingredients, components or steps.

ELEMENT NUMBER TABLE photovoltaic device assembly or kit 20 current flow21 edge piece 50 electrical element of the edge piece 51 edge connectorassemblies 52 starter piece 53 filler piece 54 end piece 55 femaleconnector housing 56 separate connector piece 58 integral photovoltaicconnector assembly 57 male connector housing 59 main body portion 60ribs 61 outer surface portion 62 inner surface portion 64 channels 65side surface portions 66 flashing portion 68 photovoltaic device(s) 100photovoltaic cell assembly 110 a photovoltaic cell 111 peripheral edge112 protective layers 113 electrical circuitry 114 body portion 120upper surface portion 122 lower surface portion 124 side wall portion126 active portion 130 inactive portion 135 positive buss terminal 140negative buss terminal 141 bottom segment 156 base portion 210 first endportion 212 second end portion 214 outer surface 216 locator portion 218main body portion 222 side body portion 224 body portion 226 spacerpiece 400 electrical output 500 pass-through electrical connectorassembly 510 electrical transmission lines in PV device 600 flow channel1100

What is claimed is:
 1. A photovoltaic device kit comprising: a. at leasta plurality of photovoltaic devices in at least a first and a second rowor column as applied to a structure, the photovoltaic device including:i. a photovoltaic cell assembly including at least one peripheral edge,at least one photovoltaic cell inboard of the at least one peripheraledge, which the photovoltaic cell includes a photoactive portion,wherein the at least one photovoltaic cell includes a surface thatallows transmission of light energy to the photoactive portion forconversion into electrical energy; ii. at least one positive bussterminal and at least one negative buss terminal for transferringcurrent to or from the photovoltaic cell assembly via at least oneintegral photovoltaic connector assembly located within the at least oneperipheral edge; and iii. a body portion including lower surface portionthat contacts the structure, and an upper surface portion that receivesa fastener that attaches the photovoltaic device to the structure,wherein the body portion is at least partially joined to at least oneedge portion of the photovoltaic cell assembly along at least a portionof a bottom segment of the body portion while leaving the surface of theat least one photovoltaic cell exposed; b. at least one edge piecedisposed at the end or within the at least upper and adjoining lower rowof photovoltaic devices, the at least one edge piece including at leastone edge connector assembly for connecting each respective row ofphotovoltaic devices; wherein a current flow across the first row orcolumn in one direction and across the second row or column in theopposite direction.
 2. The photovoltaic device kit according to claim 1,further including at least one spacer device connected between twophotovoltaic devices, one photovoltaic device and one edge piece, orboth.
 3. The photovoltaic device kit according to claim 1, wherein theat least one edge piece includes a building connector assembly orelectrical lead assembly.
 4. The photovoltaic device kit according toclaim 1, wherein the at least one integral photovoltaic connectorassembly, the at least one edge connector assembly, or both include astrain relief feature.
 5. The photovoltaic device kit according to claim1, wherein the at least one integral photovoltaic connector assembly,the at least one edge connector assembly, or both, further includes anintegral connector housing adapted to receive a connector element. 6.The photovoltaic device kit according to claim 5, wherein the connectorelement comprises: a. a base portion including a first end portion, asecond end portion, an intermediate portion and an outer surface; b. alocator portion located on the outer surface of the intermediateportion, the locator portion including a bearing wall that is shaped togenerally complement the integral connector housing; and c. at least oneelectrically conductive member that is substantially surrounded by thebase portion and that spans between the first and second end portionsand includes connective terminals at opposing ends that are shaped tointerlock with an opposing terminal in the integral connector housing,so that the bearing wall partially contacts an opposing surface in theintegral connector housing.
 7. The photovoltaic device kit according toclaim 1, wherein the at least one edge piece includes at least one edgeconnector assembly for connecting to a second edge piece.
 8. Thephotovoltaic device kit according to claim 1, wherein the at least oneedge piece includes an indicator device to communicate a circuit status.9. The photovoltaic device kit according to claim 1 wherein thestructure is a building.
 10. A photovoltaic device assembly comprising:a. a plurality of first photovoltaic devices individually interconnectedvia a plurality of photovoltaic device connector assemblies in a firstrow on a structure, wherein a current flow is created in a firstdirection; b. a plurality of discrete second photovoltaic devicesindividually interconnected via the plurality of photovoltaic deviceconnector assemblies in a second row on the structure, wherein thecurrent flow is created in an opposing direction from the current flowof the first photovoltaic devices; and c. a first edge piece spanningbetween and connecting the first and second rows at one end.
 11. Thephotovoltaic device assembly according to claim 10, including a secondedge piece spanning between and connecting the first and second rows atan opposing end, wherein at least the first edge piece includes a firstelectrical circuit that includes at least a pass-though electricalconnector or electrical lead assembly and wherein at least the secondedge piece includes a second electrical circuit that includes at leastan electrical return circuit interconnect.
 12. The photovoltaic deviceassembly according to claim 10, wherein the plurality of discrete firstphotovoltaic devices and the plurality of discrete second photovoltaicdevices comprise: a. a photovoltaic cell assembly including at least oneperipheral edge, at least one photovoltaic cell inboard of the at leastone peripheral edge, which the photovoltaic cell includes a photoactiveportion, wherein the at least one photovoltaic cell includes a surfacethat allows transmission of light energy to the photoactive portion forconversion into electrical energy; b. at least one positive bussterminal and at least one negative buss terminal for transferringcurrent to or from the photovoltaic cell assembly via at least oneintegral photovoltaic connector assembly located within the at least oneperipheral edge; and c. a body portion including lower surface portionthat contacts the structure, and an upper surface portion that receivesa fastener that attaches the photovoltaic device to the structure,wherein the body portion is at least partially joined to at least oneedge portion of the photovoltaic cell assembly along at least a portionof a bottom segment of the body portion while leaving the surface of theat least one photovoltaic cell exposed.
 13. The photovoltaic deviceassembly according to claim 12, wherein the body portion and at leastone peripheral edge at least include a unitary polymeric portion. 14.The photovoltaic device assembly according to claim 10, 11, 12, or 13according to claim 10 wherein the first edge piece and the second edgepiece comprise a polymeric body that substantially envelops at least aportion of the first and second electrical circuits respectfully. 15.The photovoltaic device assembly according to claim 10 wherein theintegral photovoltaic connector assembly includes a locator feature forlocating one of the plurality of discrete first photovoltaic devices andthe plurality of discrete second photovoltaic devices to another or tothe first or second end piece within the respective row.
 16. Thephotovoltaic device assembly according to claim 10 wherein the firstrow, second row, or both, include at least one spacer device.
 17. Thephotovoltaic device assembly according to claim 10 wherein the structureis a building.
 18. A method of constructing a photovoltaic deviceassembly on a surface of a structure, comprising the steps of: a.providing a plurality of individual photovoltaic devices, wherein theindividual photovoltaic devices include: i. a photovoltaic cell assemblyincluding at least one peripheral edge, at least one photovoltaic cellinboard of the at least one peripheral edge, which the photovoltaic cellincludes a photoactive portion, wherein the at least one photovoltaiccell includes a surface that allows transmission of light energy to thephotoactive portion for conversion into electrical energy; ii. at leastone positive buss terminal and at least one negative buss terminal fortransferring current to or from the photovoltaic cell assembly via atleast one integral photovoltaic connector assembly located within the atleast one peripheral edge; and iii. a body portion including lowersurface portion that contacts the structure, and an upper surfaceportion that receives a fastener that attaches the photovoltaic deviceto the structure, wherein the body portion is at least partially joinedto at least one edge portion of the photovoltaic cell assembly along atleast a portion of a bottom segment of the body portion while leavingthe surface of the at least one photovoltaic cell exposed; b. providinga plurality of edge pieces; c. attaching a first individual photovoltaicdevice to the surface; d. attaching a second individual photovoltaicdevice to the first individual photovoltaic device via a connectorelement; e. attaching the second individual photovoltaic device to thesurface; f. repeat steps c-e until a first row is attached to thesurface, wherein a current flow can flow in a first flow direction; g.begin attaching a second row of individual photovoltaic devices adjacentto the first row, using the same steps as the first row except that thecurrent flow is in a second flow direction; and h. attaching at leastone edge piece via a connector element to at least one end of the firstand second row.
 19. The method of constructing a photovoltaic deviceassembly on a surface of a structure according to claim 18, includingthe step of providing a spacer device.
 20. The method of constructing aphotovoltaic device assembly on a surface of a structure according toclaim 19, wherein the first row, second row, or both, include at leastone spacer device in place of at least one of the individualphotovoltaic devices.
 21. The method of constructing a photovoltaicdevice assembly on a surface of a structure according to claim 18wherein the steps c-h are repeated to create the photovoltaic deviceassembly with a plurality of rows.
 22. The method of constructing aphotovoltaic device assembly on a surface of a structure according toclaim 18 wherein a separate connector element is provided whichincludes: i. a base portion including a first end portion, a second endportion, an intermediate portion and an outer surface; ii. a locatorportion located on the outer surface of the intermediate portion, thelocator portion including a bearing wall that is shaped to generallycomplement the integral connector housing; and iii. at least oneelectrically conductive member that is substantially surrounded by thebase portion and that spans between the first and second end portionsand includes connective terminals at opposing ends that are shaped tointerlock with an opposing terminal in the integral connector housing,so that the bearing wall partially contacts an opposing surface in theintegral connector housing.
 23. The method of constructing aphotovoltaic device assembly on a surface of a structure according toclaim 18 wherein some or all of the plurality of connector elements havethe first end portion integral to the edge piece, the photovoltaicdevice, or both.
 24. The method according to claim 18 wherein thestructure is a building.